Copeland Scroll TM. ZB digital compressor

Transcription

1 Copeland Scroll TM ZB digital compressor

2 About Emerson Climate Technologies Emerson Climate Technologies, a business segment of Emerson, is the world s leading provider of heating, airconditioning and refrigeration solutions for residential, industrial and commercial applications. It combines best-in-class technology with proven engineering, design, distribution, educational and monitoring services to provide customized, integrated climate-control solutions for customers worldwide. Climate s innovative solutions, which include industryleading brands such as Copeland Scroll TM, improve human comfort, safeguard food and protect the environment. For more information, visit EmersonClimateAsia.com. Our Vision: Emerson Climate Technologies, With Our Partners, Will Provide Global Solutions To Improve Human Comfort, Safeguard Food And Protect The Environment.

3 Index Introduction 01 Digital Scroll Advantage for Rack Systems 02 Intelligent Store TM 03 Nomenclature 04 Bill of Material 04 ZBD Rack Specification 05 Operating Envelope 06 Performance Table 07 Technical Data 13 Dimensional Drawings 14 Flow Controls Parts 21 OMB Crankcase Oil Level Protective Control 21 A-W/A-F Oil Separators 22 AOFD-553 Oil Filter Drier 24 STAS Steel Liquid and Suction Line Filter Drier 25 ADKS Liquid And Suction Line Filter Drier 26 Filter-Drier Cores And Filters 28 HMI-Hermetic Moisture Indicators 29 PS1 Single Pressure Controls 31 APD Pulsation Dampener/Muffler 33 Scroll Rack Application Guidelines 34 Digital Compressor Rack Controller-XC645CX 40 Contact List 49

4 Leading Innovations in Digital Scroll Technology Emerson Climate Technologies has revolutionized the industry with the introduction of its scroll technology, which was launched in In 2012, Emerson produced its 100 millionth scroll - a significant achievement and further demonstrating Emerson s position as a world leader in the development and application of scroll technology. Energy-efficient Refrigeration Through Capacity Modulation Today, Emerson is the world s largest manufacturer of refrigeration compressors, underscoring Emerson Climate Technologies thrust of ensuring food safety and protecting the environment. Leveraging on Emerson s vast global network and R&D resources, the company also continues to develop the ultimate in climate technology for various businesses. Emerson helps provide solutions to achieve high efficiency systems for cold storage warehouses, supermarkets, quick service restaurants, meat trading and processing facilities, seafood import and export establishments, agricultural depots and retail outlets - green technologies with less environmental impact. With today s growing need to address energy efficiency and precise temperature control, Emerson developed ZBD compressors digital scroll technology in a simplified, compact design that is very reliable. The ZBD features continuous capacity modulation range of %. This eliminates hot gas bypass, which causes waste of electricity, and complications arising from variable speed drives. Precise capacity modulation control proves beneficial in a number of applications, including precise temperature control for precision cooling and humidity control as well as parallel compressor operations or rack systems intermediate and more precise part load operation of a compressor to perfectly match varying evaporator loads. Compared to cycling compressors, smoother and more precise load matching is enabled by stepless capacity control with the ZBD. Key Features and Benefits Digital Scroll technology provides higher efficiency compared to hot gas bypass systems or compressor cycling Less complicated compared to variable speed technologies More reliable compared to other modulation technologies due to elimination of oil return issues Suitable for rack systems due to its varying load requirements Proven scroll technology paired with mechanical unloading system provides greater reliability and efficiency 1

5 Digital Scroll Advantage for Rack Systems Digital scroll compressors having modulation capabilities from 10% 100% naturally fit refrigeration rack systems. Rack systems need to fulfill varying evaporator load requirements due to changing case loads, not to mention variations due to cases undergoing routine defrost. This can be attained by complementing fixed-speed compressor racks with a digital scroll of the same capacity. The refrigeration load will be matched by running fixed-speed compressors to handle the base load and the peaks by the digital scroll. This leads to a smooth and almost constant system suction pressure (see charts below). Compared to fixed-speed scroll racks where unloading is achieved by cycling the lead compressor, this results in a saw tooth profile of the system suction pressure and will reduce the life of the lead compressor due to frequent on and off action. Fluctuating suction pressures lead to varying evaporator temperature and humidity conditions a condition that is not advisable for refrigerated products. Suction Pressure Suction Pressure Time Time Compressor modulation by cycling compressor on and off Saw tooth profile of suction pressure for fixed speed compressor Compressor modulation by digital scroll Smooth system suction pressure 2

6 Intelligent Store TM ProAct Services XWeb Supervisory Platform Rack with ZB Digital Scroll Lighting and HVAC Control Superheat Controller and EEV Digital Compressor Rack Controller Power Meters Dewpoint Controller An innovative approach to enterprise facility management, Emerson s Intelligent Store architecture integrates hardware and services to help hyper mart, supermarket, convenience store, and box retail operators make better facility decisions while reducing operational costs. The Intelligent Store architecture implements best practices for facility management and transforms data from store equipment and controls into actionable insights. Designed to deliver value in both new and existing stores, the Intelligent Store architecture can help retailers significantly improve their bottom line results. The Intelligent Store solution constitutes: Energy efficient store infrastructure components State-of-the-art control technologies: XWeb Supervisory Platform Field services: Commissioning and project management Remote services: Alarm Management, Setpoint Management, Demand Response, Condition Based Maintenance, Energy Monitoring and Targeting, Smart Dispatch, Food Quality Reports and Site Administration 3

7 Nomenclature Generation Compressor Motor Protection Code Description F: Inherent internal line break motor protector Compressor Family Lubricant Blank: Mineral Oil E: Ester Oil Bill of Material High/Medium Temp Refrigeration Digital Modulation Capacity at 60Hz (Medium Temperature Condition: Btu/h) D 5 7 Motor Voltages 50 Hz 60Hz 380/ / / Base Capacity K x 1000 Compressor Motor Code Description T: Three-phase Bill of Material BOM Sight Glass Stub Tube Rotalock Digital Valve Solenoid Coil Digital Rack Controller Kit Discharge Line Temperature Sensor Condenser Mid Coil Temperature Sensor OMB OMB Adaptor 4

8 ZBD Rack Specification Family Items Unit Compressor Digital Accessory Rack Control Kit System Protector ZBD Rack Package ZBD Rack Recommendation STD BOM 10HP 15HP Digital Scroll Compressor EA ZBD38KQ ZBD38KQ Standard Scroll Compressor EA - ZB38KQ ZB38KQ - - ZB38KQ Thermistor 1 EA Valve Body EA Solenoid Coil 2 EA Controller (XC645CX) EA mA Suction Pressure Transducer EA Condenser Mid Coil Temperature Sensor EA mA Condenser Pressure Transducer 3 EA - Optional Optional TTL / RS485 Serial Converter 3 EA Hot Key EA Transformer EA Wiring Kit 3m Digital Input and Analog Out Connector 3m Oil Regulator, OMB-JB1 ASC 2 24/50 EA Adapter for ZBD Sight Glass EA HP EA - PS1-A5A PS1-A5A LP EA - PS1-A3A PS1-A3A Oil Separator EA - A-W55877 A-W55889 Oil Filter Drier EA - AOFD553 AOFD553 Filter Drier EA - Shell STAS-487T Shell STAS-489T EA - Core H-48 Core H-48 Sight Glass EA - HMI HMI Pulsation Damper EA - APD APD Notes: 1. Thermistor: Only for ZBD29KQ, PCN Solenoid coil part code 3. Please contact Emerson sales representative if the part is required Solenoid Coil Part Code Part Code Description V 50/60Hz V 50/60Hz V 50/60Hz V 50/60Hz 5

9 Operating Envelope R22 ZBD29 - ZBD Condensing Temp. o C Evaporating Temp. o C Notes: 1. Envelope in unshaded region, max return gas temperature of 18.3 C 2. Envelope in shaded region, max superheat of 11K only R404A ZBD29 - ZBD Condensing Temp. o C Evaporating Temp. o C Note: 1. Envelope in unshaded region, max return gas temperature of 18.3 o C 6

10 Performance Table Q=Capacity (kw) P=Power input (kw) 3-Phase R22 50 Hz Compressor Condensing Temperature o C Evaporating Temperature ( o C) ZBD29KQ ZBD38KQ ZBD45KQ Q P Q P Q P Notes: Suction Return Temperature 18.3 o C Suction Superheat 11.0K Liquid subcooling 0.0K 7

11 Performance Table Q=Capacity (kw) P=Power input (kw) 3-Phase R22 50 Hz Compressor Condensing Temperature o C Evaporating Temperature ( o C) ZBD48KQ Q P Notes: Suction Return Temperature 18.3 o C Suction Superheat 11.0K Liquid subcooling 0.0K 8

12 Performance Table Q=Capacity (kw) P=Power input (kw) 3-Phase R404A 50 Hz Compressor Condensing Temperature o C Evaporating Temperature ( o C) ZBD48KQE ZBD45KQE ZBD38KQE ZBD29KQE Q P Q P Q P Q P Notes: Suction Return Temperature 18.3 o C Liquid subcooling 0.0K 9

13 Performance Table Q=Capacity (kw) P=Power input (kw) 3-Phase R22 60 Hz Compressor Condensing Temperature o C Evaporating Temperature ( o C) ZBD29KQ ZBD38KQ ZBD45KQ Q P Q P Q P Notes: Suction Return Temperature 18.3 o C Suction Superheat 11.0K Liquid subcooling 0.0K 10

14 Performance Table Q=Capacity (kw) P=Power input (kw) 3-Phase R22 60 Hz Compressor Condensing Temperature o C Evaporating Temperature ( o C) ZBD48KQ Q P Notes: Suction Return Temperature 18.3 o C Suction Superheat 11.0K Liquid subcooling 0.0K 11

15 Performance Table Q=Capacity (kw) P=Power input (kw) 3-Phase R404A 60 Hz Compressor Condensing Temperature o C Evaporating Temperature ( o C) ZBD48KQE ZBD45KQE ZBD38KQE ZBD29KQE Q P Q P Q P Q P Notes: Suction Return Temperature 18.3 o C Liquid subcooling 0.0K 12

16 Technical Data 3-Phase Model ZBD29KQ ZBD29KQE ZBD38KQ ZBD38KQE ZBD45KQ ZBD45KQE ZBD48KQ ZBD48KQE 50Hz TF5 TF5 TF5 TF5 TFD TFD TFD TFD Motor type TF5 TF5 TF5 60Hz TF7 TF7 TF7 TF7 TFD TFD TFD TFD Displacement (m³/hr) 50Hz Hz Hz TF TFD LRA TF Hz TF TFD Hz TF TFD Max Operating Current TF Hz TF TFD Hz TF TFD Max Continuous Current TF Hz TF TFD TF KQ TF RLA TFD TF KQE TF TFD TF Oil Charge, L TF TFD TF Oil Recharge, L TF TFD Nominal power(hp) Crankcase Heater(W) Connection Tube size(inch) Discharge Tube outer Diameter 1/2 1/2 1/2 3/4 Suction Tube outer Diameter 7/8 7/8 7/8 7/8 Dimension(mm) Length Width Height Mounting parts installation size (hole size, mm) 190 x 190 (8.5) Net Weight(kg) Sound Power (dba)

17 Dimensional Drawings ZBD29KQ/E (BOM558) 14

18 Dimensional Drawings ZBD38-45KQ/E (BOM 558) 15

19 Dimensional Drawings ZBD48KQ/E (BOM 558) 16

20 Dimensional Drawings ZBD29KQ/E (BOM 559) 17

21 Dimensional Drawings ZBD38-48KQ/E (BOM 559) 18

22 Dimensional Drawings ZBD38-45KQ/E (BOM 458 & 459) 19

23 Dimensional Drawings ZBD48KQ/E (BOM 458 & 459) 20

24 Flow Controls Parts OMB Crankcase Oil Level Protective Control The OMB is a compressor crankcase oil level protective control ideal for use with Copeland Scroll models ZF, ZB, ZR and ZS. It is also recommended for Copeland brand products, Carlyle, Bitzer, and other semi-hermetic compressors. Features Precision oil level measurement for maximum protection Easy monitoring with alarm and status lights Foam resistant design prevents nuisance trips unlike optical sensor designs Contaminant proof operation ensures accurate control Only approved oil level control for Copeland Scroll Compressors 5-time lockout feature protects compressor from repeated low oil level condition Self-contained unit with oil lever sensor and integral solenoid to manage oil level supply Reverse Hall-effect sensor for precise measurement of oil level and protection from sensor magnetic debris contamination SPDT output contact for compressor shut-down and alarming Easy installation by sightglass replacement Adapters suitable for various types of scroll compressors (not required for reciprocating compressors) UL Recognized (File Number: MP604) Fluorescent floating ball Integral sight glass Debris retention magnet for reliable operation Ordering Information: PCN Description Oil Management Control OMB-JB1 ASC 2 24/ STD OMB-MO1 ASC 2 24/ STD Adapters (to attach OMB to Copeland Scroll compressor for new installation only) OMB-ACA ADAPTER (3/4 x 14 NPTF) Copeland Glacier, ZF, ZS, ZB OMB-ACB ADPATER (1 1/8 x 12 UNF) Copeland A/C ZR OMB-ACD ADAPTER (1 1/4 x 12 UNF) Copeland A/C Summit Series OMB-ACE ADAPTER (1 3/4 x 12 UNF) Copeland Specter Series OMB-AUA Copeland 6D Semi-Hermetic OMB-ASA Carlyle Compressors DA, DR, 5F, 5H, 06D and 06E Service parts Inlet Flare Screen Sight Glass O-Ring Mounting O-Rings (3 pieces) KS Solenoid Repair Kit Specifications OMB Series Maximum working pressure: 640 psi Solenoid MOPD: 350 psi Supply voltage: 24 VAC, 50/60 Hz Solenoid coil: ASC 2L 24 VAC, 50/60 Hz Current consumption: 0.6A Time delay for low level signalling: 5 10 seconds Time delay for after setpoint recovery: 5 10 seconds Alarm delay time: 120 seconds Alarm switch: SPDT Alarm contact rating: 10A at 125; 5A at 220 VAC 50/60 Hz Refrigerant compatibility: HFC, HCFC, CFC Oil temperature: 180 F Max. Storage and transport temperature: 140 F Max. Operating ambient temperature: 120 F Max. Oil supply fitting: 1/4" Male SAE UL/CUL file number: SA8547 Transformer VA requirements* 25" *NOTE: Field supplied transformer should always be of the same primary voltage as the electrical supply system. Nomenclature example: OMB-JB1 ASC /60 OMB JB1 ASC /60 Oil Management Control JB1 - Junction Box MO1 - Series Relief Connector Dimensional Data (mm): Solenoid Coil Model Number Voltage, Frequency (Included)

25 A-W/A-F Oil Separators The A-W and A-F are used for multiple compressor racks in supermarkets and air conditioning systems for use with HCFCs, HFCs and their lubricants. Features Hermetic welded or accessible bolted flange construction Solid copper connections Corrosion resistant epoxy powder paint Nomenclature: A W Series W = Welded F = Flanged Model Number Connection Size ( in 1/8") A-F Series Ordering Information and Capacity Table: Description R-12 R-22/R-407C R-502 R-134a R-404A/R-507 FLANGED PCN SEALED PCN -40 o C 40F (4C) -40F/C 40F (4C) -40F/C 40F (4C) -40F/C 40F (4C) -40F/C 40F (4C) Tons kw Tons kw Tons kw Tons kw Tons kw Tons kw Tons kw Tons kw Tons kw Tons kw A-F A-W A-F A-W A-F A-W A-F A-W A-F A-W A-F A-W A-W A-F A-W A-F A-W *See replacement parts page. Repair kits for style 2 only. Seal Units: A-W Description A-W Style No. Connection Size (inch) 1/2 ODF Dimensions (in) A-W /8 ODF A-W /8 ODF 16.3 A-W /8 ODF 19.5 A B 10.8 A-W /8 ODF 13.2 A-W /8 ODF 19.9 A-W /8 ODF 15.8 A-W /8 ODF A-W /8 ODF Replaceable Float PCN Oil Pre-charge Amount (0%) N/A 17.0 N/A

26 Flanged Units: A-F Description Style No. Connection Size (inch) Dimensions (in) A B C Replaceable Float PCN Oil Pre-charge Amount (0%) A-F /2 ODF 10.5 A-F /8 ODF 15.0 A-F /8 ODF A-F /8 ODF N/A 17.0 A-F /8 ODF 21.4 A-F /8 ODF 21.8 A-F /8 ODF A-F /8 ODF Dimensional Data (mm): 3/8 SAE FLARE FOR OIL RETURN ON ALL UNITS INLET AND OUTLET IS ON TOP OF UNIT 127 INLET AND OUTLET IS ON TOP OF UNIT STYLE NO. 1 STYLE NO. 2 STYLE NO

27 AOFD-553 Oil Filter Drier The AOFD is designed specifically for refrigerant systems that use POE oil. POE oil is hygroscopic in nature, which means that it attracts and absorbs water. Moisture in a closed system can produce acid and will harm the compressor. The AOFD protects compressors by removing moisture and trapping contaminants. Features Designed to clean and dry POE Oil 3/8 male flare connections for easy replacement Large filter surface area to provide maximum filtration Contains desiccant for moisture removal Designed to operate at a very low pressure drop 10 micron filtration for optimum oil cleaning Dual access valves for pressure drop monitoring AOFD-553 Series Specifications UL/CUL file number: Maximum working pressure: SA psig AOFD Water Capacity Table Refrigerant Type Drops at 125 F Ordering Information PCN Description R AOFD-553 Oil Filter Drier R-134A 518 R-404A 518 R-407C 435 Dimensional Data 9.62" 7.50" 3.17" 24

28 STAS Steel Liquid and Suction Line Filter Drier The STAS is a replaceable core Filter Drier for CFC, HCFC, and HFC refrigerants for use in large commercial air conditioning and refrigeration systems. Features Slotted cover/unique internal hardware for hassle-free installation Full fl ow fi ttings for low pressure drop Corrosion resistant epoxy powder paint finish Sturdy steel shells for long life Solid copper connections 100 mesh outlet screen Filtration (with core): 40 microns Maximum working pressure: SV version= 34.5 bar T version = 47 bar UL/CUL fi le number: SA7175 Nomenclature: STAS 48 9 T STAS Series Steel Take-Apart Series Unit Size (in 3 ) Connection Size (in 1/8") System Service T = Liquid Line Service SV = Suction Line Service Ordering Information And Dimensional Data (mm): PCN Description Size (mm) A B C D Number of 48 in 3 Cores STAS-485T STAS-487T STAS-489T STAS-4811T STAS-4813S-V STAS-4817S-V STAS-4821S-V STAS-4813T STAS-4811SV STAS-967T STAS-969T STAS-9611T STAS-9613T STAS-9617T STAS-9617S-V STAS-9621S-V STAS-9625 SV STAS-1449T STAS-14411T STAS-14413T STAS-14417T STAS-19211T STAS-19213T STAS-19217T STAS-1927/5T /16.0 Note: 1. SV style include stainless steel bolts and access valve

29 ADKS Liquid And Suction Line Filter Drier The ADKS is a replaceable core Filter Drier for use with CFC, HCFC, and HFC refrigerants in very large commercial air conditioning and refrigerant systems Features Full flow fittings for low pressure drop Corrosion resistant epoxy powder paint fi nish Sturdy steel shells for long life durability Dimensional Data ADKS Series Specifications Filtration (with core): 40 microns Maximum working pressure: 500 psig* UL/CUL fi le number: SA 3124 Bolt Torque: 35 ft-lbs *Note: Not suitable for R-410A applications above 500 psig. Nomenclature: ADKS T System Protector Series Unit Size (in cu. in.) Connection Size (in 1/8") T = Tap Access Connection ADKS Models are shipped without fi lter cores or filter drier cores. See filter or filter drier cores for availability. Ordering Information PCN Description Connection Size Number Of 100 in 3 Cores Dimensions (mm) A B C D E F 2 G H 1 Weight (kg) ADKS-30013T 1 5/8 ODF ADKS-30017T 2 1/8 ODF ADKS-40017T 2 1/8 ODF ADKS-40021T 2 5/8 ODF Notes: *Does not include weld bead 1 H Dimension is the clearance required to change the internal hardware assembly T = 1/4 FPT access connection 26

30 Capacity Table (in Tons) Liquid Line for Replaceable Block Type ADKS Filter Driers Type Connection Size (inch) Flow Capacity at 0.07 bar pressure drop 1,2 (kw) R-12 R 134a R 22/R 410A R 407C R 404/507 R-502 ADKS 30013T 1 5/8 ODF ADKS 30017T 2 1/8ODF ADKS 40017T 2 1/8ODF ADKS 40021T 2 5/8ODF Notes: 1 All ratings in accordance with ARI Standard F liquid refrigerant temperature 5 o F saturated vapor temperature 3.1 lbs./min./ton for R-134a 2.9 lbs./min./ton for R-22 and R-407C 4.0 lbs./min./ton for R-404A/507 and R-12 2 For 2 PSI ΔP. Multipy values by 1.4 Replacement Parts Exploded View Flange Cover Description PCN ADKS-300 ADKS-400 X ADKS 30017T 2 1/8ODF 121 Shell Strainer Assembly ADKS-300 X ADKS-400 X Miscellaneous Parts INLET BLOCK RETAINER FILTER-DRIER BLOCK Gasket Set (Includes cover gasket) X FILTER-DRIER BLOCK GASKET FILTER-DRIER BLOCK SHELL STRAINER ASSEMBLY 27

31 Filter-Drier Cores And Filters Universal replacement cores and filter cores for use in our ADKS and STAS shells and similar competitive Take-Apart type Filter Drier shells. May not be used for BTAS. Features Water capacities to suit specific system conditions Exceptional acid capacities for normal system protection, or to effectively clean-up following a compressor burnout Activated carbon blend for soluble contaminant and wax removal (W-HH Series) Nomenclature: H 48 Cores And Filters Series (in 3 ) Ordering Information: PCN Type Refrigerant Function Water Capacity 1 (g) R 134a R 22 R 407C R 404A /R 507 R 410A 24oC 52oC 24oC 52oC 24oC 52oC 24oC 52oC 24oC 52oC D-48 HCFC High Acid Removal H-48 HCFC High Acid and Water Removal W-48-HH HCFC, HFC Burnout Cleanup UK-48 CFC, HCFC, HFC H-100 HCFC Universal Replacement High Acid and Water Removal W-100-HH HCFC, HFC Burnout Cleanup F-48 HCFC, HFC Filter (Suction Only) F-100 HCFC, HFC Filter (Suction Only) - Note: 1. Water Capacities are based on Equilibrium Point Dryness (EPD) of: 50 parts per million for R 134a, R 404A/R 410A and R 407C, 60 parts per million for R 22 Dimensional Data (mm): Filter drier block size Dimensions (mm) A B C Weight (kg) Filter drier block size Dimensions (mm) A B C Weight (kg) F48/F48R F

32 HMI-Hermetic Moisture Indicators The HMI is designed to provide an accurate method of determining the moisture content of a system's refrigerant. The HMI has a unique high accuracy moisture indicator for CFC, HCFC, and HFC refrigerants. Features Highest sensitivity moisture indicator available Hermetic, leak-free construction Single indicator for all common refrigerants Accurate color calibration at low ppm levels and higher temperatures Wide angle viewing/high visibility window for ease of monitoring All brass corrosion resistant body for fewer leaks Solid copper connections HMI Series Specifications Maximum working pressure: 680 psig UL/CUL file number: SA 9566 Nomenclature: HMI 1 TT 4 Hermetic Moisture Indicator Series Connection Style TT = Sweat x Sweat Connection Size (in 1/8") Dimensional Data B A A B B C D C D TYPE "MM" MALE FLARE X MALE FLARE TYPE "FM" FEMALE FLARE X MALE FLARE E A F A F E C D C D F TYPE "TT" TUBE STUB X TUBE STUB G TYPE "TTMF" TUBE STUB MALE X TUBE STUB FEMALE 29

33 Dimensional Data (mm): PCN Description Series HMI-1MM2 Connection Size (inch) HMI-1MM3 3/ HMI-1MM4 Male Flare x Male Flare 1/ HMI-1MM5 5/ HMI-1MM6 3/ HMI1-1TT HMI1-1TT3 3/ HMI1-1TT4 1/ HMI1-1TT5 Sweat x Sweat (ODF) 5/ HMI1-1TT6 3/ HMI1-1TT7 7/ HMI1-1TT9 1 1/ HMI-1FM HMI-1FM3 Female Flare x Male Flare 3/ HMI-1FM4 1/ HMI-1TT2MF HMI-1TT3MF 3/8 Sweat x Sweat (ODM x ODF) HMI-1TT4MF 1/ HMI-1TT5MF 5/8 1/4 1/4 1/4 1/4 Moisture Content Color Code (ppm H 2 O): Indication Liquid Temperature Dry (Dark Blue) Caution (Purple) Wet (Salmon) 75 F 100 F 125 F 75 F 100 F 125 F 75 F 100 F 125 F R R-134A R R-407C R-410A R-404A/

34 PS1 Single Pressure Controls PS1 Single Pressure Controls are designed for use on high and low pressure applications in refrigeration, airconditioning, and heat pump systems, providing single-device control of the compressor or other electrical device. Features Adjustable pressures and differentials Narrow adjustable differential depending on model Range and differential pointer in units bar and psig Range and differential individually lockable by tab High rated SPDT contacts for all versions Captive terminal and cover screws Manual toggle for system checkout and override Options Different pressure connections Automatic and manual reset versions Factory set to customer specification Specifications PS1 Series SPDT switch rated for 12FLA and 72LRA at 240VAC and 16FLA and 96LRA at 120VAC Agency approvals include: UL/CUL file number E85974 CE per (LVD) low voltage directive Nomenclature: PS1 A 5 K Product Name Housing Variant/function Pressure Range Sensor Type PS1 = Adjustable single Pressostat A = Pressure control, automatic B = Pressure cut out, external manual reset EN R = Pressure control, external manual reset W = Pressure limiter, automatic, DIN/EN = -0.3 to 7 bar 4 = 2 to 20 bar 5 = 6 to 31 bar A = 7/16-20 UNF male for 1/4 SAE male flare K*= 7/16-20 UNF flare nut with 1 meter (3 ft.) cap tube U = 6mm ODF solder, 80mm length R = 1/4" male, brass for 1/4" BSPP Fitting 31

35 Ordering Information Single Pressure Control PCN Pressure Range (bar) Differential (bar) Factory Setting (bar) Function Pressure Connection PS1 - A3A to 7 1 to Automatic 1/4" SAE male flare PS1 - A3K to 7 1 to Automatic 1m cap tube with nut PS1 - A3R to 7 1 to Automatic 1/4" BSPP fitting PS1 - A3U to 7 1 to Automatic 6mm tube, 80mm length PS1 - A4A to 20 3 to Automatic 1/4" SAE male flare PS1 - X4A to 20 3 to Automatic 1/4" SAE male flare PS1 - A5A to 31 3 to Automatic 1/4" SAE male flare PS1 - A5K to 31 3 to Automatic 1m cap tube with nut PS1 - B5U to 31 3 to PS1 - R5A to 31 Fixed 20 External Manual Reset External Manual Reset 6mm tube, 80mm length 1/4" SAE male flare PS1 - W5U to 31 3 to Automatic 6mm tube, 80mm length Bracket Note: Bracket not included with controls. Sold separately. 100 brackets per box. Dimensions and Drawings mm(in): 32

36 APD Pulsation Dampener/Muffler The APD series is designed to reduce noise and vibration on the compressor discharge lines. Features Compact size Full flow fittings Solid copper connections Corrosion resistant epoxy powder paint fi nish Rugged steel shells for vibration resistance Shock resistant steel shell construction Specifications Maximum working pressure: 680 psig Operating Range: -40 F to +250 F UL/CUL fi le number: SA 5760 Nomenclature: APD 05 3 S B APD Series Pulsation Dampener Cubic Inches Fitting Size in 1/8 ODF Fittings With Baffles (omit for standard) Flow Capacity Fitting Size Tons 1/ / / / / /8 35+ Ordering Information Fitting Size Tons Dimensions (in) A B C D E F APD 1R APD 054 S-B APD 163 S APD 165 S-B APD 309 S Dimensional Data 33

37 Scroll Rack Application Guidelines 1. Introduction Parallel operation is when several compressors are operating on one common refrigeration system. These installations require a special design to achieve a maximum possible operating capacity and reliability. Only the system design engineer can make the decision which configuration of installation is to be used in view of the particular requirements. The concept of scroll compressors for refrigeration in parallel operation brings several benefits: Efficient capacity control With several compressors in parallel, if one of the compressors is turned off, one can achieve a simple method of capacity control combined with a maximum possible saving of energy. If the load or ambient conditions change, compressors can be switched on and off to match capacity requirements. This method of capacity control provides the advantage that the application limitations are not altered as when the plant is equipped with capacity control. The use of unequal compressors allows many capacity possibilities. Standby operation If one compressor cannot run for any reason, the load can often be met by the remaining compressors. If the stoppage is caused by a compressor breakdown, the other compressors could be damaged as well. One has to take immediate action to protect the whole installation if acid / dirt is generated. The cause has to be detected in order to be able to decide on the urgency of repair. This is especially required on plants having oil and refrigerant vapour pressure equalization lines, and on plants having no oil level regulating system with filters in the suction and oil return lines. Changing compressors If a compressor needs to be changed for any reason the small lightweight nature of the scroll makes this a much less costly operation and causes much less disruption. This is particularly true for the smaller models. Matching several evaporating conditions If there are two or more temperatures to be controlled individual compressors can be matched to each evaporator while working on a single condenser circuit. This will give power savings compared with an alternative system working at the lowest suction pressure. Scroll compressors have no positive displacement oil pump and therefore no oil pressure switch. The high performance Teflon bearings provide protection for short periods in case of oil losses. However sustained running at high-pressure differences without lubricant will fail the bearings. In order to ensure adequate protection it is necessary to observe the following guidelines. 2. Parallel application considerations If compressors are required to operate in parallel it is normally necessary to stop and start them independently for capacity control purposes. There are three major considerations in this type of application: Oil return With all capacity controlled refrigeration plant the oil circulation has to be perfectly correct especially under part-load operation. This means that the maximum possible capacity reduction will be limited by the means of guaranteeing the correct oil circulation. An adequate oil level at all times is necessary to maintain lubrication of the bearings. Too much oil can result in inefficient operation and excessive oil carry over to the system. Tubing stress If compressors are mounted close together care must be taken to ensure that there is sufficient flexibility in the tubing. If this is not done the starting pulse may result in excess stress directed at the mounting positions and may give rise to a leak. Tube resonance should be avoided. Running sequence A certain logical sequence control is recommended so that each compressor runs for the same amount of time. 34

38 3. Active oil control Individual oil control for each compressor can be attained when each compressor has Flow Controls OMB oil level regulator fitted using an adaptor at the sight glass location. The regulator is fed from an oil reservoir which is itself fed from an oil separator. Filters can be installed in the oil feeding line. The reservoir allows variations in oil quantity in the system to be accommodated. Oil carried over from the compressor to the system is replaced when insufficient oil is being returned. There is a sight glass on each oil level regulator where the oil level can be visually checked approximately 10 seconds after switching off the compressor. This method is recommended by Emerson Climate Technologies provided that certain design points are observed. Because the scroll compressor has no positive displacement oil pump and therefore no oil pressure switch, it is recommended that the oil control system incorporates protection. It will be necessary to add oil to the system and the Emerson Climate Technologies approved lubricants are Emkarate RL 32-3MAF and Mobil EAL Arctic 22 CC. The oil level regulating system for applications should be installed on site. Well tested oil level regulating systems are available from refrigeration wholesalers. 3.1 Low pressure oil reservoir The oil reservoir is maintained at a pressure slightly above the compressor sump pressure and this limits the amount of refrigerant dissolved in the oil in the reservoir. The pressure drop is low when the oil enters the compressor and the amount of flash gas formed in the sump is small. Float switches or other devices can be used as regulators. It is recommended that the regulator has an electrical output which can be wired into the control circuit and stop the compressor if the oil level falls below the minimum level and remains below the minimum level for a period of time (maximum 2 minutes). This protects against failure of the oil supply to the individual compressor. A level switch in the reservoir will only protect against insufficient oil in the receiver, but not against loss of oil supply to an individual compressor or against a fault on an individual regulator. Regulators currently on the market which meet these requirements include Flow Controls OMB oil level regulator. The OMB requires the oil reservoir to be pressurized to 3.5 bar above suction pressure for reliable operation. When using a regulator care must be taken to set the oil level in the upper half of the sight glass. If an adapter is used to connect the regulator this may have a smaller internal diameter than the glass and this could give rise to a false oil level reading. When commissioning these systems it is important to allow sufficient time for equilibrium running conditions to be attained. Because the oil carry over rate from the scroll compressors is low it may take some time for stable oil quantities to build up in the coolers. Until this has happened the total oil requirement of the system cannot be determined. 3.1 High pressure oil reservoir The need for a separate oil receiver may be avoided if a combined separator/receiver is used, but in this case the oil will be stored at discharge pressure. It will therefore cause much more disturbance and foaming when it enters the compressor sump. For this reason it is advisable to limit the quantity of oil entering the sump when the valve opens. Flow Controls OMB oil level regulator is suitable for this type of application and has been proven to operate satisfactorily with a high-pressure oil supply. 4. Passive oil control 4.1 Equalisation lines with passive oil control The need for a separate oil receiver may be avoided if a combined separator/receiver is used, but in this case the oil will be stored at discharge pressure. It will therefore cause much more disturbance and foaming when it enters the compressor sump. For this reason it is advisable to limit the quantity of oil entering the sump when the valve opens. Flow Controls OMB oil level regulator is suitable for this type of application and has been proven to operate satisfactorily with a high-pressure oil supply. Simple systems which link the compressor sumps via tubes with no control are obviously attractive. They are quite common on air conditioning applications, but in refrigeration additional considerations apply. They can of course only be considered for compressors working at a common suction condition. If there are large variations in oil quantity in the system due to changing conditions or defrost, this may result in too much or too little oil in the compressors. Usually the only means of checking oil level is via the sight glass connection. Once the oil level is above the sight glass it is not possible to determine if the maximum oil quantity is reached. Likewise if no oil is visible in the sight glass there is a danger of operation below the minimum quantity. A tube connecting the oil level adjustment valves on the compressors is not adequate because when a compressor is stopped, the pressure in the shell rises and oil will transfer to the running compressor(s). The adjustment valve is located below sight glass level and therefore the stationary compressor will show no oil level. Even if all compressors run together at all times, there will be small pressure differences which will cause the same effect. 35

39 Alternative methods using the sight glass connections for oil equalisation connections have been shown to work on specific systems. Notes are given below on some possible methods, but because of wide variations in system design and operating conditions, these methods cannot be given general approval by Emerson Climate Technologies. The user has to verify operation in each system type. 4.2 Gas and oil equalization tube at sight glass position Emerson Climate Technologies has conducted tests to prove the satisfactory operation of up to three compressors in parallel using a gas and oil equalising tube. The configuration of suction line and equalization line should be as described below (see sections 4.3 and 4.4). This method can be used for: Two or three ZF, ZS, ZB refrigeration Scroll compressors They must all be the same model, not uneven sizes All voltages Refrigerants R404A, R507, R22 Same operating envelope as single compressor with injection where required Adequate liquid floodback protection must be provided Any sequence of compressors is allowed Figure 1: Scrolls in parallel Table 2: Model applicability Low temperature 4.3 Suction line configuration Compressor models approved An adequately sized suction header providing equal distribution of returning refrigerant and oil to each individual compressor must be used. The nonsymmetrical design as shown below is acceptable and does not create oil level problems between the compressors. Medium temperature ZF09K* to ZF48K* ZB15K* to ZB114K* ZS21K* to ZS11M* Figure 2: Oil return Figure 3: Suction line configuration 36

40 4.4 Oil equalization line The oil equalization line between the two or three compressors must be at least 7/8 (22 mm) with a minimum inner diameter of 19 mm. On no account must the internal diameter of any fitting in this line be less than 19 mm. It is strongly recommended that a sight glass be fitted using adaptors. Kits consisting of the adaptor shown below, plus conversion to brazed connections are available (see spare parts lists for details). The equalization tube must be level, and the compressors must be mounted level. Tests have shown that smaller tube diameters do not provide proper oil balancing. An oil separator may be used and the oil return line from the separator should be connected to the oil equalization line. If no oil separator is installed the oil returns into the suction header and is picked up there from the individual compressor suction lines. 11/4 12 UNF 3/4 14 NPTF 7/8 Figure 4: Adaptor for oil sight glass connection NOTE: Tightening torque: Nm. Use Loctite string or Everseal 483 White Pipe Sealant. 4.5 Oil and gas equalization plus oil regulator If the OMB or other device is fitted to the equalization line, one device serving 2 or 3 compressors, the proper functioning of the system has to be checked to ensure that no nuisance tripping occurs. The OMB sight glass, remote from the sump, does not always accurately follow the sump oil level. The oil separator must be of the combined separator/reservoir high-pressure type, or alternatively a separate oil reservoir may be used if the separator has its own float valve. The separator float valve outlet must not be connected directly to the OMB. 5. Oil return to running compressors If oil returns to the compressor at approximately the same rate as it leaves then the oil level will be maintained. It is always preferable to design the suction manifold in such a way that oil returning with the suction gas can only enter the running compressor(s). This can be done in a number of ways. Perhaps the most common is to use a suction header with vertical pick-ups to each compressor which induces sufficient velocity to lift the oil. Again certain designs have been shown to be satisfactory but each one has to be proven by testing. With some system designs this is sufficient to ensure adequate oil level at all times but there is no fail-safe pressure switch if one compressor loses oil. Recommended Not recommended From evaporator(s) From evaporator(s) From evaporator(s) Suction lines to compressors Figure 5: Suction header/lines to compressors Recommendation 37

41 6. Tubing and mounting considerations 6.1 Starting pulse The standard mount for the scroll compressor is a soft rubber mount. It is designed to transmit the lowest possible disturbance to the mounting frame. Because of the flexibility of this mount, it is essential that tubing to each compressor be designed to accommodate the movement which will occur, particularly upon start-up. The three phase motors used in the refrigeration scroll compressors exhibit a high starting torque characteristic. The reaction of the stator is directly on the shell because there are no internal spring mounts. This reaction causes easily observable movement of the shell when the standard mounts are used and this is normal. However, if the suction and discharge tubing of the compressor is closely clamped to the frame or linked to another compressor, the tubing will restrain the movement and the motor reaction force will be taken by the tubing. This may cause excessive stress and premature failure of tubing joints. 6.2 Resonance The discharge pulse can in some configurations give rise to resonance of tubing. It is advisable to avoid a natural frequency of between 45 and 55 Hz for the section of tubing between the compressor and the first clamp. It is often not possible to determine this in advance but in the unlikely event of a resonance problem arising a change in tube configuration will usually resolve it. 6.3 Recommendations for tubing and mounting Always allow some flexibility in the tubing to the suction and discharge connections. If the standard mounts are used there should be at least two bends and a vertical section before the tube joins a header. Test the finished assembly by rocking the compressor on its mounts. Vibration eliminators may be used but are not essential if the tubing has sufficient flexibility. Vibration eliminators should be fitted in the vertical plane. An alternative harder mount as detailed in Figure 7 is recommended. This will allow more loads to be transmitted via the feet, and the very small additional vibration transmission is not usually a problem in refrigeration applications. It is still advisable to incorporate a vertical section of tube between the compressor and the first rigid mount. This will give flexibility and minimise the risk of resonance. Figure 6: Tubing recommendation Compressors Ident Number Characteristics Drawing ZB15K* to ZB45K* ZF09K* to ZF18K* ZF13KVE to ZF18KVE ZS21K* to ZS45K* Durometer ZB56K* to ZB11M* ZF24K* to ZF48K* ZF24KVE to ZF48KVE ZS56K* to ZS11M* Variation = Hard steel 38

42 Compressors Ident Number Characteristics Drawing ZB50K* to ZB114K* Summit Variation = Hard steel Figure 7: Mounting parts for multiple operation 7. Design points 7.1 Suction line header The suction lines running from the evaporators to the compressors should be led to a common main suction header in which the suction pressures can equalize. From the main suction header to the compressors, preferably short and similarly constructed pipes have to be provided symmetrically arranged. This serves to achieve a most perfect pressure equalization necessary for the crankcases already at the compressor inlet. Naturally, the lower the speed in the suction line header the more perfect the pressure equalization. Pipes running into the suction line header must not be right opposite outgoing pipes, so that an equalization of the returning oil quantities can take place in the suction line header. According to the capacity requirement of the system, compressors will be switched on or off. Occasionally however liquid refrigerant can possibly flow into the compressors operating. Therefore, the suction line header should be designed in a manner to simultaneously serve as a liquid separator. Consequently, one has to construct each pipe from the suction line header to the compressor so that the oil return is guaranteed by using additional bores or capillaries. Liquid refrigerant should not return to the compressors when not operating via the oil returning device. Since installations with parallel compressors mostly have long pipe runs fitted on site, suction filters are commonly used. These filters may just as well be equipped with drier cores as with dust filters only. The filter housings will be rigidly fitted into the system during first installation before the common suction line header. Thus one can employ the appropriate filter core according to the individual requirement, ie, acid absorbing driers too if necessary. 7.2 Discharge line header The discharge line should slope downwards from the compressor to a lower positioned discharge line header. This is so any liquid returning to the compressor from the condenser on the off cycle does not enter the compressor discharge port. 7.3 Oil separator One of the features of a parallel compressor installation is the higher refrigeration capacity. With an increasing capacity generally the entire pipe work is extended, more complex and not easy to survey, sometimes resulting in problems with the oil return. It is therefore recommended to install oil separators regardless of the refrigerant and evaporating temperature. Pay careful attention and obey the rules on how to install the pipe work. With the installation using an oil level regulating system the oil separator is already included in this system hence the oil return line has to be fitted to the oil reservoir. 7.4 Oil supply The more complex a system pipe work is the more influence the installation has on oil return. The extreme possibilities of capacity control resulting in frequent changes of gas velocities inside the suction line will render the oil return difficult as well. Particular attention should be paid to the lubrication problems involved. The oil level in the compressor crankcase should be controlled by using an OMB oil level regulator having oil level detection. This device interrupts the compressor control circuit when insufficient oil is in the compressor crankcase. 7.5 Installation All compressors should be installed as close as possible to each other in order to keep the lines as short as possible. By changing the priority of compressors in operation and keeping running time constant the compressors oil temperature can be kept at a certain level which will reduce the amount of refrigerant absorbed into the compressor oil. Refrigerant flowback into the compressor during standby periods is not possible because the suction line header is below the compressor inlet port. If there is a requirement for isolating the installation against vibrations the frame should be mounted on vibration absorbers. Of course the connecting pipes on suction and discharge sides have to be flexible as well. 39

43 Digital Compressor Rack Controller-XC645CX General Description The XC645CX is designed to manage both compressors and fans in a condensing system such as a pack. The compressors can be digital scroll, simple, multistage. Control is by means of a neutral zone or proportional band and is based on the pressure or temperature sensed in the LP suction (compressors) and HP (condenser) circuits. A special algorithm balances the run hours of the compressors to distribute the work load uniformly. The controllers can convert both LP and HP pressures and displays them as temperatures. The front panel offers complete information on the system s status by displaying the suction and condenser pressure (temperatures), the status of the loads, possible alarms or maintenance conditions. Each load has its own alarm input that is able to stop it when activated. To guarantee the total system s safety, there are also two inputs for low and high pressure switches: when these are activated, the system is stopped. By means of the HOT KEY the controller can be easy programmed at power on. The controller can be connected to the X-WEB, controlling and monitoring system, thanks to the serial TTL output, using the standard ModBus RTU protocol. Components Related to the XC645CX Name Description Part Number Transformer TF5 230V/12Vac CD Wiring kit 1.5m and 3m Female disconnect able connector for digital input or analog output (4pcs) CWC15-Kit (1,5m) CWC30-Kit (3,0m) CABCJ15 (1,5m) CABCJ30 (3,0m) DD DD DD DD TTL /RS485 serial converter XJ485CX+CABRS02 J7MAZZZ9AA 4-20mA suction pressure transducer PP11 ( bar) BE mA condenser pressure transducer PP30 (0 30bar) BE Hot key for programming HOT KEY 4K DK CWC15KIT and CWC30KIT: wiring kits The XC645CX is provided with 2 socket connectors with 14 and 6 pins. For the wiring the CWC15KIT (1.5m cable length) or CWC30KIT (3.0m cable length) have to be used. 40

44 CABCJ15 or CABCJ30: 2 PIN connectors NOTE: Use the connection cable CABCJ15 (1.5m lenght) or the CABCJ30 (3.0m lenght) for the: HP digital input (25-26), i2f configurable digital input (27-28), 0-10Vdc or 4-20mA analogue output (23-24) oa6, 12Vdc/40mA digital output (21-22) : PP07, PP11, PP30 PP50: 4 20mA pressure transducers PP07 2,0MT bar rel FE cod BE PP11 2,0MT bar rel FE cod BE PP30 2,0MT bar rel FE cod BE PP50 2,0MT bar rel Male cod BE NP4-67: pipe mounting temperature probe The NP4-67 temperature probe can be used on the discharge line to monitor the discharge temperature of the Digital Scroll compressor. NP MT NTC probe Measurement range: C, Cable 1,5mt Code BN XJ485CX: TTL / RS485 serial converter The XJ485CX is a TTL/RS485 external converter. Insert it into the TTL receptacle to convert the TTL output into a RS485 (+) and (-) signal for the monitoring system MODBUS_RTU compatible. (XWEB). 41

45 Wiring and Electrical Connections General warnings Before connecting cables make sure the power supply complies with the instrument s requirements. Separate the probe cables from the power supply cables, from the outputs and the power connections. Do not exceed the maximum current allowed on each relay 5A resistive, in case of heavier loads use a suitable external relay. Wiring connections 24Vac/dc supply: use terminals 1-2 Always use a class 2 transformer with minimum power 5VA such as TF5. Terminals [21-22], [23-24], [25.26], [27-28] are provided with JST 2 PINS connectors, they require the CABCJ15 (1,5mt) or CABCJ30 (3mt) wiring cables Probes connection If using terminal ends be sure there are no bear parts which could cause short circuiting or introduce noise disturbance at high frequencies. To minimize the induced disturbances use shielded cables with the shield connected to earth. Pressure probe (4-20 ma): respect the polarity. If using terminal ends be sure there are no bear parts which could cause short circuiting or introduce noise disturbance at high frequencies. To minimize the induced disturbances use shielded cables with the shield connected to earth. Temperature probe: it is recommended to place the temperature probe away from direct air streams to correctly measure the temperature. Low voltage side (14PINs connector): Keep the cables away from the power cables. Use shielded cable to lengthen the cables. NOTE 1: The PIN 4 is the common line for the temperature probes NOTE 2: The PIN 3 gives a 12Vdc supply for the 4-20mA pressure transducers PP07 PP11, PP30, PP mA pressure transducers respect the polarity. Suction (P1C = Cur) Brown (+) to terminal 6 ; white (-) to terminal 5 Condenser (P2C = Cur) Brown (+) to terminal 6 ; white (-) to terminal 7 Pb V 40mA Pb2 42